Diaper including ink-printed substrate web

ABSTRACT

A disposable diaper including an ink-printed substrate web exhibiting ink rub-off resistance. The substrate web is printed with an ink composition to form an ink film on the substrate web. The ink film is coated with a coating composition to form a coating film on the ink film. At least one of the ink composition and the coating composition forms a cross-linked structure within the film thereof and forms a cross-linked structure with the other composition between the ink film and the coating film. A method for making the diaper includes the steps of printing and coating the ink film.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of co-pending application Ser. No.10/439,546 filed on 16 May 2003, which is hereby incorporated in itsentirety herein by reference.

FIELD OF THE INVENTION

The present application relates to a disposable diaper including anink-printed substrate web exhibiting improved ink rub-off resistance anda method for making such a diaper.

BACKGROUND OF THE INVENTION

An ink-printed substrate web is broadly used in various consumerproducts. For example, in personal care products such as disposablegarments, it is often desired to provide graphic designs printed with anink on the outside of the disposable garment to enhance the aestheticappearance and the consumer acceptance and to make the diaper look morelike a conventional baby garment. For this purpose, an ink-printedsubstrate web, which could be a polymeric film or a nonwoven fibrousweb, is used for the outermost layer of the disposable garment.

One problem of the ink-printed substrate web is poor ink rub-offresistance. Ink rub-off is typically caused by abrasion of the ink withother substances such as clothes of the wearer of a disposable garment,a carpet on the floor or the like. One method of solving this problem isto print the graphics on an inner substrate web such as a film or anonwoven to be covered by an outer substrate web. As the printed surfaceof the inner substrate web is covered with the outer substrate web, theprinted graphic on the inner substrate web does not get abraded directlywith other contacting substrates and ink rub-off does not occur. Whilethe substrate web covering the printed surface of the inner substrateweb contributes to reduce the abrasion of the printed surface, the outersubstrate web tends to hide the graphics printed on the inner substrateweb to make the graphics to have hazy appearance. The fibers in anonwoven if a nonwoven is used for the outer substrate web appear verydistinctively on the printed graphics when covering a dark coloredgraphics. This also limits the vivid color expression of the graphic.

Yet another way of circumventing the problem of ink rub-off is to putthe printed surface inside and the non-printed surface outside such thatthe printed surface is not abraded. In this case, however, the substrateweb itself printed with the graphics tends to hide the graphics. Thus,there is a need for an ink-printed substrate web having an ink-printedsurface which can be exposed to abrasion, yet exhibiting good inkrub-off resistance.

Attempts have been made to improve ink rub-off resistance on a substrateweb, e.g., in U.S. Pat. No. 5,458,590 issued on Oct. 17, 1995 toSchleintz et al. titled “INK-PRINTED, LOW BASIS WEIGHT NONWOVEN FIBROUSWEBS AND METHOD”, U.S. Pat. No. 5,695,855 issued on Dec. 9, 1997 to Yeoet al. titled “DURABLE ADHESIVE-BASED INK-PRINTED POLYOLEFIN NONWOVENS”,and U.S. Pat. No. 5,853,859 issued on Dec. 29, 1998 to Levy et al.titled “ROOM TEMPERATURE LATEX PRINTING”. However, the existing art maynot provide all of the advantages and benefits of the present invention.

SUMMARY OF THE INVENTION

A disposable diaper includes an ink-printed substrate web exhibiting inkrub-off resistance. The substrate web is printed with an ink compositionto form an ink film on the substrate web. The ink-printed substrate webis coated with a coating composition to form a coating film on the inkfilm. At least one of the ink composition and the coating compositionforms a cross-linked structure within the film thereof and forms across-linked structure with the other composition between the ink filmand the coating film. A method for making a disposable diaper includingthe ink-printed substrate web exhibiting ink rub-off resistance is alsoprovided.

These and other features, aspects, and advantages of the invention willbecome evident to those skilled in the art from a reading of the presentdisclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the presentinvention will be better understood from the following description ofpreferred embodiments taken in conjunction with the accompanyingdrawings in which:

FIG. 1 is a back view of one embodiment of a disposable pull-on diaperhaving an ink-printed substrate web with exemplary graphics;

FIG. 2 is a simplified plan view of the pull-on diaper of FIG. 1 in itsflat, uncontracted state prior to formation;

FIGS. 3 and 4 are schematic diagrams of the bending propertymeasurement;

FIG. 5 is a graph showing the bending hysteresis curve; and

FIG. 6 is a schematic diagram explaining the fuzz level measurement.

DETAILED DESCRIPTION OF THE INVENTION

All percentages herein are by weight of compositions unless specificallystated otherwise. All ratios are weight ratios unless specificallystated otherwise. As used herein, the term “comprising” means that othersteps and other ingredients which do not affect the end result can beadded. This term encompasses the terms “consisting of” and “consistingessentially of.”

The ink-printed substrate web of the present invention exhibits improvedrub-off resistance. The ink-printed substrate web is preferably used forconsumer products, such as personal care products including disposableabsorbent articles.

As used herein, the term “absorbent article” refers to devices whichabsorb and contain body exudates, and, more specifically, refers todevices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody.

The term “disposable” is used herein to describe absorbent articleswhich are not intended to be laundered or otherwise restored or reusedas an absorbent article (i.e., they are intended to be discarded after asingle use and, preferably, to be recycled, composted or otherwisedisposed of in an environmentally compatible manner). The disposableabsorbent article could include, but not limited to, a diaper forinfants, a diaper for adult incontinent persons, incontinence briefs,incontinence garments, diaper holders and liners, feminine hygienegarments, training pants, and the like. Further, the ink-printedsubstrate web of the present invention may be used for any type ofconsumer products.

The ink-printed substrate web should have excellent ink rub-offresistance. An ink-printed substrate web with poor ink rub-offresistance is problematic because the removal of the ink from theprinted substrate web contributes to a deterioration in the quality ofthe ink-printed graphics on the substrate web or a transfer of the inkfrom the ink-printed substrate to other substrates.

As used herein, “ink” refers to any liquid composition or componentsthereof applied onto the substrate web and which remains thereon in avisible pattern even though components of the ink may evaporate.

The term “rub-off” refers to the transfer of color from the surface of aprinted substrate web. Ink rub-off is typically due to abrasion.Abrasion refers to the ability to remove ink from a substrate web bymechanically scuffing the ink from the surface of the substrate web.

Ink rub-off can be a problem especially when printed on polyolefinpolymer based substrate web such as a nonwoven made of polyolefinfibers. Polyolefin homo-polymers such as polypropylene, polyethylenehave very low surface energy as compared to conventional substrates likecellulose, nylon or poly (ethylene terephthalate). This makes the inkcomposition difficult to adhere to the surface of the polyolefin polymerbased substrate web. Further, unmodified homopolymer polyolefin polymerssuch as polypropylene and polyethylene do not have any chemical reactivesite for the ink composition to anchor with the polymer. Thus,unmodified polyolefin polymer based substrate web typically providesinsufficient binding force for an ink composition to resist the frictionapplied to the ink-printed substrate web due to its inherently poorsurface energy and/or chemical structure while the polyolefin polymerbased substrate web is beneficial in several aspects compared with othercommercial polymers, such as cost, processability into a form of fibersor films, or softness in the form of fibers or films. While polyolefinpolymers can be modified to have a reactive site throughcopolymerization, radiation grafting or the like, these polymers are notcommercially available yet.

Another aspect causing ink rub-off problem can be an ink itself.Typically, an ink composition comprises a coloring agent, a binderpolymer, a solvent and other additives. The coloring agent such as apigment is dispersed in a binder polymer dissolved in a solvent. The inkcomposition forms an ink film on the substrate web which in turnconsists of several sub-layers of resin mixed with pigment. If thebinding between these sub-layers is insufficient to bind each sublayers,these sublayers get removed gradually during abrasive contact with othersubstrates. Thus, the poor binding between the sub-layers of the inkfilm also contributes to the poor rub-off resistance of the ink on thesubstrate web.

The ink-printed substrate web of the present invention comprises threekey elements; a substrate web to be printed, an ink composition used forprinting the substrate web, and a coating composition used for coatingthe printed ink. The substrate web may be applied with a coronadischarging treatment prior to printing the ink composition on thesubstrate web to raise a surface energy of the substrate web. The inkcomposition is used to print the substrate web and to form an ink filmlayer on the substrate web. The coating composition is used to coat theink-printed area of the substrate web and to form a coating film layeron the ink film. The coating film is preferably a transparent such thatthe ink film layer is visible through the coating film. However, thecoating film may be translucent as far as the ink film layer is visible.

Herein, the term “ink film” or “ink film layer” refers to a solid inkfilm structure which is left behind by evaporating a solvent in the inkcomposition. The term “coating film” or “coating film layer” refers to asolid coating film structure which is left behind by evaporating asolvent in the ink composition.

The ink composition comprises a first binder polymer and a firsthardener, and the first binder polymer and the first hardener form across-linked structure within the ink film layer such that the bindingbetween each sublayer of the ink film improves. The coating compositioncomprises a second binder polymer and a second hardener and the secondbinder polymer and the second hardener form a cross-linked structurewithin the coating film layer such that the binding between eachsublayer of the coating film improves. The term “sublayer” refers to thethinnest unit of the film layer which contains all the ingredients ofthe film layer as a whole. The first binder polymer of the inkcomposition may form a cross-linked structure with the second hardenerof the coating composition such that the cross-linked structure isformed between the ink film and the coating film to strengthen thebinding therebetween. Alternatively, the second binder polymer of thecoating composition may form a cross-linked structure with the firsthardener of the ink composition such that the cross-linked structure isformed between the ink film and the coating film to strengthen thebinding therebetween.

Preferably, the first binder polymer of the ink composition forms across-linked structure with the second hardener of the coatingcomposition and the second binder polymer of the coating composition mayform a cross-linked structure with the first hardener of the inkcomposition. Most preferably, the first binder polymer of the inkcomposition forms a cross-linked structure with the first hardener ofthe ink composition and with the second hardener of the coatingcomposition and the second binder polymer of the coating compositionforms a cross-linked structure with the first hardener of the inkcomposition and with the second hardener of the coating composition.When the ink composition comprises the first binder polymer and thefirst hardener and the first hardener can form a cross-linked structurewith the second binder polymer of the coating composition, the coatingcomposition may not necessarily contain the second hardener.

Alternatively, when the coating composition comprises the second binderpolymer and the second hardener and the second hardener can form across-linked structure with the first binder polymer of the inkcomposition, the ink composition may not necessarily contain the firsthardener. If either composition lacks a hardener, the coating layerpreferably comprises a binder polymer and a hardener while the inkcomposition comprises a binder polymer without a hardener because thecoating film faces outside of the substrate web and should be tough toresist abrasion. As far as a binder polymer and a hardener can form across-linked structure, any type of binder polymer and any type ofhardener may be used. Further, the first binder polymer and the firsthardener may be the same as the second binder polymer and the secondhardener respectively.

The substrate web to be printed with an ink composition may include anytype of substrate, such as a nonwoven, a woven fabric, a film, or alaminate comprising thereof. In one embodiment, the substrate web to beprinted with an ink composition may be a nonwoven web which may be usedfor consumer products such as an outermost layer of disposable absorbentarticles. The ink-printed nonwoven web is preferable for the use of theoutermost layer of disposable absorbent articles to provide a cloth-likefeeling and aesthetically appealing appearance.

Preferably, the ink-printed surface of the nonwoven web is exposedoutside of disposable absorbent articles. The ink-printed nonwoven maybe laminated with a liquid impermeable film comprising a polymeric filmwhich serves as a barrier to liquid in disposable absorbent articles.The ink-printed nonwoven may be laminated outside of the polymeric filmsuch that the ink-printed surface is exposed outside of disposableabsorbent articles.

Alternatively, the ink-printed nonwoven may be laminated outside of thepolymeric film such that the ink-printed surface comes in contact withthe polymeric film. If the ink-printed nonwoven has liquidimpermeability or is treated to be liquid impermeable, the ink-printedliquid impermeable nonwoven may be used for a liquid impermeable barrierof disposable absorbent articles without requiring an additionalpolymeric film. The substrate web to be printed with an ink may beselected depending on the purpose of the use in consumer products.Exemplary substrate webs are a multi-layered nonwoven, a stretchablenonwoven, a liquid impermeable polymeric film, a liquid permeablepolymeric film, a vapor permeable polymeric film, a vapor impermeablepolymeric film, a stretchable film, a multi-layered film, a laminatecomprising a nonwoven and a polymeric film, a woven fabric, or the like.A nonwoven web is particularly preferable for use of consumer productssuch as an absorbent article.

The nonwoven web may comprise any type of fibers such as natural fibers(e.g., wood or cotton fibers), synthetic fibers (e.g., polyolefins,polyamides, polyester fibers), or a combination of natural and/orsynthetic fibers. The fibers may have any shape such as a circular crosssection shape or a non-circular cross section shape, preferably anon-circular cross section shape. The fiber denier can be any of rangedepending up on the end use. Polyolefin polymer based nonwoven isbeneficial in several reasons such as cost, processability into a formof fibers, or softness in the form of fibers.

The nonwoven web can be made by any known methods. It may be made bybonding of web-like arrays of fibers or filaments. The web may be madefrom fibers of discrete length ranging from few millimeter to few metersby carding or wet or air laying process or they may be produced bylaying or blowing filaments as they are being melt extruded. The fabricsmade by these latter process are commonly known as spunbonded orspunlaid and melt-blown nonwoven webs. A spunbonded nonwoven web may bedefined generically as continuous filament fibrous structures which aremade in the form of fabrics, sheets or tapes and are prepared fromsynthetic polymers in a process integrated with fiber manufacture. Amelt-blown nonwoven web is a fibrous structure produced by extruding apolymer melt through a die into a high velocity stream of hot air toproduce fine or super fine fibers which are deposited on a moving screenafter quenching. A carded nonwoven web is made from carded fibers. Thepreferred polymers for the production of filaments or fibers for makingthe nonwoven web are polyolefins such as polyethylene or polypropylene.In one embodiment, a preferred nonwoven web for the use of the outermostlayer of disposable absorbent articles may be a spunbonded nonwovencomprising polypropylene fibers with a basis weight of between about 9g/m² and about 110 g/m². An exemplary nonwoven web for the use of thepresent invention is supplied by Mitsui Chemical in Japan under thedesignation code of PC-0220 (commercial name: Mitsui Copoly PP Nonwoven20 gsm).

The poor surface energy of the substrate web is one of the reasons forpoor surface adhesion of the ink composition to the substrate web. Asmentioned above, unmodified polyolefin polymers have very low surfaceenergy because of their non polar nature. It is very difficult to makean ink or a lacquer bond effectively to the surface of the polyolefinpolymer based substrate web. For example the surface energy of freshlymade polypropylene based substrate web is in the range of about 29dynes/cm. For a good surface adhesion of the printing ink, the surfaceenergy of the substrate web is preferably appreciably higher than theprinting ink. The substrate web surface energy is preferably about 40dynes/cm or higher, more preferably about 42 dynes/cm or higher for asolvent-based ink.

The substrate web is processed by a corona discharging treatment toincrease the surface energy of plastic substrate web. In coronadischarging treatment, electrons are accelerated into the surface of thesubstrate web causing the polymer molecular chains on the surface of thesubstrate web to rupture, producing multiplicity of open ends and freevalances. The free valances are then able to form carbonyl groups withthe oxygen atoms from the ozone created by the electric discharge. Thisincreases the surface energy of the substrate web and improves adhesionto the printing ink.

In the corona discharging treatment, the substrate web is fed into acontrolled air-gap between two electrodes, one of which is energizedwith high voltage electrical field and the other of which is grounded.As high voltage power is applied across the electrode, the air-gap andthe substrate, the air in the gap becomes ionized from the accelerationof electrons to form a gaseous conductor comprising corona. The ionizedair-gap induces an electron avalanche which in turn creates oxidativemolecules such as ozone. The ozone oxidizes the surface of the substrateweb and increases the surface energy and surface adhesion. An importantfactor which needs to be controlled is the extent of polymer chainrupture which occurs during the corona discharging treatment to avoidany adverse effect to the substrate web. For example, when the substrateweb is a nonwoven web which is porous, the corona discharging treatmentneeds to be controlled to avoid any adverse effect on the mechanicalintegrity of the nonwoven web. A fine optimization of the coronadischarging treatment in terms of the treatment power, surface energyand material mechanical integrity needs to be maintained. The coronadischarging treatment can be made at corona discharging treatment powerof between about 20 W·m²/min. and about 60 W·m²/min., preferably betweenabout 40 W·m²/min. and about 60 W·m²/min., more preferably between about40 W·m²/min. and about 58 W·m²/min. The corona discharging treatment canbe applied by, e.g., Sherman Corona Treater supplied by ShermanTreaters.

The substrate web applied with corona discharging treatment is thenprocessed by a printing process. The printing process may be any knownprocess such as flexographic printing, ink-jet printing, screenprinting, or rotogravure printing. Flexographic printing is preferablebecause of the suitability of the method in printing soft substrates aswell as considering the speed of production and cost factors.Flexographic printing process uses a raised printing surface made of aflexible material to transfer an ink image to the substrate web. Theflexible surface is able to transfer a good image even to a roughsubstrate web. The printing may be made in either mono-color ormulti-color. A liquid ink is used which may be solvent or water based,and dries mainly by evaporation.

The ink composition comprises two components; a first base component anda first hardening component. The first base component comprises acoloring agent, a binder polymer (first binder polymer), a solvent andother additives if desired. The first hardening component comprises ahardener (first hardener) and a solvent and other additives if desired.Instead of the first base component, the fist hardening component maycontain a coloring agent. Alternatively, both first base component andfirst hardening component may contain a coloring agent. Based uponweight of the total ink composition, suitable addition ranges for thefirst base component ranges from about 60% to about 100%, preferablyfrom about 70% to about 95%, more preferably from about 80% to about95%. Based upon weight of the total ink composition, suitable additionranges for the first hardening component ranges from about 0% to about40%, preferably from about 5% to about 30%, more preferably from about5% to about 20%. A suitable first base component and a suitable firsthardening component are preferably in the form of a liquid at roomtemperature (i.e., a temperature of about 20° C.).

The coloring agent of the first base component may be generally termedas pigments which refers to insoluble color matter used in finelydispersed forms. The pigments may be dyes, organic pigments or inorganicpigments. Exemplary organic pigments may include: C.I. Pigment Yellow 1,C.I. Pigment Yellow 3, C.I. Pigment Yellow 13, C.I. Pigment Red 5, C.I.Pigment Red 7, C.I. Pigment Red 12, C.I. Pigment Red 112, C.I. PigmentRed 122, C.I. Pigment Blue 1, C.I. Pigment Blue 2, C.I. Pigment Blue 16,C.I. Vat Blue 4, C.I. Vat Blue 6, or Carbon black. Exemplary inorganicpigments may include: titanium dioxide (e.g., Pigment White 6), carbonblack (e.g., Pigment Black 7), iron oxides, ferric oxide black (e.g.,Pigment Black 11), chromium oxide, or ferric ammonium ferrocyanide.Exemplary dyes may include: Solvent Yellow 14, Dispersed Yellow 23,Metanil Yellow, Solvent Red 111, Dispersed Violet 1, Solvent Blue 56,Solvent Orange 3, Solvent Green 4, Acid Red 52, Basic Red 1, SolventOrange 63, or Jet Black. Based upon weight of the total first basecomponent, the suitable addition range for the coloring agent is fromabout 1% to about 49%, preferably from about 3% to about 30% morepreferably from about 5% to about 20%.

The binder polymer of the first base component preferably has at leasttwo or more functional groups (open reactive groups) such as hydroxylgroups which can react with the hardener of the first hardeningcomponent to form a high molecular weight cross-linked film of the inkwhen printed on the substrate. If the binder polymer and the hardenerare tri-functional, the resulting cross-linked molecules will havehigher molecular weight. The binder polymer of the first base componentmay be epoxy, polyols, styrene-butadiene, ethylene vinyl acetates,ethylene vinyl chlorides, acrylates, styrene acrylates, pure phenolics,polyvinyl butyral resin, and mixtures thereof. Epoxy or polyols arepreferable. Based upon weight of the total first base component,suitable addition range for the binder polymer is from about 10% toabout 50%, preferably from about 10% to about 40%, more preferably fromabout 10% to about 30%.

Epoxy resins may be defined as glycidyl ethers of polyhydroxy compounds.Typical polyhydroxy compounds which may be used include bisphenol A(common name for 4,4′-isopropylidene bisphenol), ring substitutedbisphenol A, resorcinal, hydroquinone, phenol-formaldehyde novolacresins, aliphatic diols such as ethylene glycol, propylene glycol,1,4-butanediol, 1,6 hexanediol glycerol, poly(oxyethylene)glycol,poly(oxypropylene)glycol, linear glycidyl epoxy resins derived fromdihydric phenols, and the like.

Polyols may be any organic hydroxy compound, having a functionality oftwo or more that is soluble in the solvents employed. Such polyhydroxycompounds can include simple aliphatic polyols, polyether polyols,phenolic resins, and mixtures of these. Exemplary polyols may includepolyhydroxy functional straight or branched chain saturated orunsaturated hydrocarbons, optionally comprising one or more oxy or estermoieties and optionally comprising one or more heterocyclic atoms,aromatic and/or heterocyclic rings, the heterocyclic atom(s) beingselected preferably from N, O and S. Suitable polyol reactants includemany commercially available materials well known to the skilled of theart. Preferred chain-extendible, crosslinkable polyols includeepoxy-diol adducts which can be provided as the reaction product of asuitable diepoxide with a suitable diol, and polyurethane resin withhydroxyl groups.

The solvent of the first base component may comprise a single componentof solvent, or a mixture solvent comprising two or more components ofsolvent. The type of the solvent is preferably determined consideringthe solubility of the binder polymer and/or the drying time of the inkin terms of the printing machinery drying efficiency. Preferably, thesolvent used in the first base component is a mixture of solvents. Thesolvent system may consist of a mixture of one or more of the followingcomponents: water; alcohols such as 2-propanol, 1-propanol, and ethanol;acetates such as ethyl acetate and propyl acetate, butyl acetate;glycols such as propylene glycol; and glycol ethers such as propyleneglycol mono methyl ether.

The ink composition also may contain other additives, such as pH controlagents, viscosity modifiers, defoamers, dispersants, printing presshygiene control agents, preservatives, and/or corrosion control agents.Waxes is preferable as an additive to improve the slip properties ofink. Exemplary waxes may include: natural waxes such as carnauba wax,beeswax, Japan wax, shellac wax; petroleum waxes such as slack wax,scale wax, ceresin wax; synthetic waxes such as polyethylene,polytetrafluroethylene, fatty acid amides. Cellulose nitrate, shellac,silica, etc. can also be added as an additive.

The hardener of the first hardening component forms a cross-linkedstructure with the binder polymer of the first base component for theink composition. The ink composition forms an ink film on the substrateweb which in turn consists of several sub-layers of resin mixed withpigment. The cross-linked structure contributes to bind each sub-layersuch that each sublayer does not get readily removed during abrasivecontact with other substrates to improve rub-off resistance of the inkcomposition. Further, the hardener of the first hardening componentpreferably forms a cross-linked structure with the binder polymer of thesecond base component for the coating composition explained hereinbelowto bind the outermost sublayer of the ink composition and the innermostlayer of the coating composition which contact to one another. Basedupon weight of the total first hardening component, the suitableaddition range for the hardener is from 0% to about 40%, preferably fromabout 5% to about 30%, more preferably from about 5% to about 15%.

The hardener may be a solution polymer consisting of a cationicpolyamine-epichlorohydrin polymer, primary diamine curing agent, orpolyisocyanate with free isocyanate groups. Primary diamine curing agentis preferably used with the binder polymer consisting of epoxy resins.Polyisocyanate with free isocyanate groups is preferably used with thebinder polymer consisting of polyols.

Suitable polyisocyanates may be any organic polyisocyanate having 2 ormore NCO groups per molecule. Suitable such polyisocyanates include, forexample, 2,4-toluenediisocyanate, 2,6-toluenediisocyanate, hexamethylenediisocyanate, p,p′-diphenylmethanediisocyanate, p-phenylenediisocyanate,hydrogenated methylene diphenyldiisocyanate, naphthalene diisocyanate,dianisidine diisocyanate, polymethylene polyphenyl-isocyanate, mixturesof one or more polyisocyanates and the like.

The solvent of the first hardening component may comprise a singlecomponent of solvent, or a mixture solvent comprising two or morecomponents of solvent. The type of the solvent is preferably determinedconsidering the solubility of the hardener and/or the drying time of theink in terms of the printing machinery drying efficiency. Preferably,the solvent used in the first hardening component is a mixture ofsolvents. The solvent system may consist of a mixture of one or more ofthe following components: water; alcohols such as 2-propanol,1-propanol, and ethanol; acetates such as ethyl acetate and propylacetate, butyl acetate; glycols such as propylene glycol; and glycolethers such as propylene glycol mono methyl ether.

Typically the first base component for the ink composition and the firsthardening component for the ink composition are mixed to form an inkcomposition prior to printing. Depending on the ink composition, thebinder polymer and/or the hardener used, the speed of cross-linkingvaries. An optimized ink composition should have a pot life ranging from8-10 hours. After the two components are mixed to form an inkcomposition, the ink is printed on the substrate web. The substrate webare then dried to evaporate the solvents of the ink composition. Thechemical curing of the printed ink will happen during the aging periodunder a normal room temperature (i.e., 25° C.). The aging temperatureand time to achieve complete curing will vary according to the hardenerand ink composition used. The speed of the curing can also be increasedby the use of catalysts. Alternatively, the curing may be performedafter the coating composition is applied on the ink composition. Thus,the ink-printing is made on a substrate web. The ink composition forms afilm on the substrate web which in turn consists of several sub-layersof resin mixed with pigment. The cross-linked structure of the inkcomposition binds each sublayers such that the sublayers are readily notremoved during abrasive contact with other substrates.

The ink composition printed on the substrate web is further coated witha coating composition. The coating composition covers the outermostsublayer of the ink composition with some pigments on the surface whichmight get rubbed-off during a frictional contact with an abrasivesurface. To prevent or at least reduce such rub-off or removal ofcolored ink from the ink film on the substrate web, a transparent overprint coating is provided to cover the ink composition. The coatingcomposition forms a high molecular weight cross-linked transparent filmover the ink film printed on the substrate web. The coating compositionforms a high molecular weight cross-linked structure within the coatingcomposition, and preferably forms a cross-linked structure with the inkcomposition. This will create a secured and strong transparent coatingfilm which protects the ink film sublayers from getting rubbed-off.Further, because the coating composition does not contain any pigmentsor contains only minimal amount of pigments to maintain the transparencyof the coating, the coating composition forms a smooth surface whichfurther reduces the coefficient of friction of the surface of thecoating when come in abrasive contact with other surfaces to improve theink rub-off resistance.

The coating composition comprises two components; a second basecomponent and a second hardening component. The two component system maybe the same as that of the ink composition except that the coatingcomposition does not contain a coloring agent in it. The second basecomponent comprises a binder polymer (second binder polymer), a solvent,and other additives if desired. The second hardening component comprisesa hardener (second hardener), a solvent, and other additives if desired.The binder polymer of the second base component and the hardener of thesecond hardening component are selected to form a cross-linked structurewithin the coating composition. The binder polymer of the second basecomponent is preferably selected to form a cross-linked structure withthe hardener of the first hardening component of the ink composition.The hardener for the second hardening component is also preferablyselected to form a cross-linked structure with the binder polymer of thefirst base component of the ink composition. This allows to form across-linked structure between the outermost layer of the inkcomposition and the innermost layer of the coating composition and toprovide a binding strength between the ink layer and the coating layer,thereby improving the rub-off resistance of the ink composition. Thebinder polymer of the second base component may be selected from thecomponent which is chemically similar to, preferably the same as thebinder polymer of the first base component for the ink composition. Thehardener of the second hardening component for the coating compositionmay be selected from the component which is chemically similar to,preferably the same as the hardener of the first base component for theink composition. Alternatively, the binder polymer and the hardener forthe coating composition may be selected from the component which isdifferent from the binder polymer and the hardener for the inkcomposition. The solvent for the second base component and the secondhardening component may be any type of solvent, preferably similar to,more preferably the same as the solvent for the first base component andthe first hardening component for the ink composition, respectively.

Based upon weight of the total second base component, the suitableaddition range for the binder polymer is from about 10% to about 50%,preferably from about 10% to about 40%, more preferably from about 10%to about 30%. Based upon weight of the total second hardening component,the suitable addition range for the hardener is from 0% to about 40%,preferably from about 5% to about 30%, more preferably from about 5% toabout 15%.

A preferable example of the two component ink system comprisespolyurethane polymer with hydroxyl groups in the chain end as well as inthe branches for a binder polymer and polyisocyanate for a hardener. Thebinder polymer along with a coloring agent and suitable printingadditives are dissolved in a suitable solvent mixture to form a firstbase component. The hardener is also dissolved in a suitable solventmixture to form a first hardening component. The first base componentand the first hardening component are then mixed prior to printing. Theink composition thus formed is printed on the substrate and over coatedwith a transparent coating composition which comprises two components. Apreferable example of the two component coating system comprises thesame components as the ink composition except that the coatingcomposition does not contain the coloring agent. The printed and overcoated substrate is then dried by evaporating the solvent and then agedfor cross-linking in the ink composition and the coating composition andbetween the ink composition and the coating composition.

Referring to FIG. 1, there is shown one embodiment of a consumer productutilizing an ink-printed substrate web with exemplary graphics. FIG. 1shows a disposable diaper which is a pull-on diaper 50. The pull-ondiaper 50 is generally pulled onto the body of the wearer by insertingthe legs into the leg openings 62 and pulling the article up over thewaist. Alternatively, the disposable diaper may be a conventionalopen-type taped diaper with an adhesive tape fastening system and/or amechanical tape fastening system.

Referring to FIG. 2 as well, the diaper 50 generally comprises abacksheet 52, a topsheet 54 and an absorbent layer 66 located betweenthe backsheet 52 and the topsheet 54. The topsheet 54 is located to beplaced facing the body or nearest the body when the diaper is worn andis generally provided with a liquid permeable region so that bodyexudates can flow through the topsheet 54 to the absorbent layer 66. Thebacksheet 52, which is placed away from the body during wear, istypically liquid impermeable so that outer clothing or other articlesare not wetted by the body exudates. The backsheet 52 comprises amicroporous polymer film 53 and a layer of nonwoven material 55laminated to the outside of the microporous film 53 in which case thereis provided a more cloth-like and garment-like feel than is typicallyobtained with a film backsheet only. The backsheet 52 is printed withgraphics 20. The diaper 50 has elastically extensible side panels 56provided to ensure more comfortable and contouring fit by initiallyconformably fitting the pull-on diaper 50 to the wearer and sustainingthis fit throughout the time of wear well past when it has been loadedwith exudates. Leg elastics 58 and waist elastic region 60 are alsoprovided to enhance the fit around the legs and waist, respectively. Theside panels 56 are joined at seams to form a waist opening 63 and legopenings 62. As will be understood by those of skill in the art, manyother features for disposable absorbent articles are within the scope ofthe present invention. For example, barrier cuffs as described in Lawsonand Dragoo U.S. Pat. Nos. 4,695,278 and 4,795,454 are a desirablefeature for disposable absorbent articles. In addition, skin care-typetopsheets that are provided with lotion thereon for the purpose ofreducing skin irritation and chafing are a desirable feature herein.

The graphics 20, 22 are printed on the backsheet 52. Preferably, thegraphics 20, 22 are printed on the outer surface (garment facingsurface) of the nonwoven 55 of the backsheet. The nonwoven 55 ispreferably applied with a corona discharging treatment to raise itssurface energy to improve adhesion of an ink composition to the surfaceof the nonwoven as described above. The nonwoven 55 is then printed withan ink composition and coated with a coating composition as describedabove. Alternatively, the graphics 20, 22 may be printed on the innersurface (i.e., microporous film facing surface) of the nonwoven 55, ormay be printed on the outer surface (i.e., nonwoven film facing surface)of the microporous film 53.

FIG. 1 shows the back view of the diaper 50 with an exemplary graphic 20positioned in about the upper region of the nonwoven 55 of the backsheet52, on the back side of the diaper 50. In FIG. 2, there is shown asimplified plan view of an embodiment of a disposable absorbent articlein its flat, uncontracted state prior to formation. In this embodiment,the graphic 20 is shown in the back region of the diaper with graphics22 additionally shown in the front region. The graphics 20 and 22 arepreferably registered to be positioned on the predetermined position ofthe diaper 50 such that the graphics 20 and 22 appear on the sameposition on each diaper without significant variation. Each diaper maybe printed with the same pattern of the registered graphics.Alternatively, each diaper may be printed with two or more differentpatterns of the registered graphics. The graphics 20 and/or 22 may beprinted with a mono-color ink or multi-color inks. Further, the printingmay be made on other portions of the diaper such as a landing zone for afastening tape, a barrier cuff, a back ear portion, and/or a front earportion.

Referring to FIG. 2, the topsheet 54 and the backsheet 52 have lengthand width dimensions generally larger than those of the absorbent core66. The topsheet 54 and the backsheet 52 extend beyond the edges of theabsorbent core 66 to thereby form the periphery of the diaper 50. Thetopsheet 54, the backsheet 52, and the absorbent core 66 may beassembled in a variety of well known configurations.

The absorbent core 66 may be any absorbent member which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. The absorbent core 66 may be manufactured in awide variety of sizes and shapes (e.g., rectangular, hourglass,“T”-shaped, asymmetric, etc.) and from a wide variety ofliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles such as comminuted wood pulp which is generallyreferred to as airfelt. Examples of other suitable absorbent materialsinclude creped cellulose wadding; chemically stiffened, modified orcross-linked cellulosic fibers; tissue including tissue wraps and tissuelaminates; absorbent foams; absorbent sponges; superabsorbent polymers;absorbent gelling materials; or any equivalent material or combinationsof materials. The configuration and construction of the absorbent core66 may vary (e.g., the absorbent core may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones; or maycomprise one or more layers or structures). Further, the size andabsorbent capacity of the absorbent core 66 may also be varied toaccommodate wearers ranging from infants through adults. However, thetotal absorbent capacity of the absorbent core 66 should be compatiblewith the design loading and the intended use of the diaper 50.

The topsheet 54 is preferably positioned adjacent the inner surface ofthe absorbent core 28 and is preferably joined thereto and to thebacksheet 52 by attachment means (not shown) such as those well known inthe art. In a preferred embodiment of the present invention, thetopsheet 54 and the backsheet 52 are joined directly to each other inthe diaper periphery and are indirectly joined together by directlyjoining them to the absorbent core 66 by any suitable attachment means.

The topsheet 54 is preferably compliant, soft feeling, andnon-irritating to the wearer's skin. Further, the topsheet 54 ispreferably liquid pervious permitting liquids (e.g., urine) to readilypenetrate through its thickness. A suitable topsheet 54 may bemanufactured from a wide range of materials such as woven and nonwovenmaterials; polymeric materials such as apertured formed thermoplasticfilms, apertured plastic films, and hydroformed thermoplastic films;porous foams; reticulated foams; reticulated thermoplastic films; andthermoplastic scrims. Suitable woven and nonwoven materials can becomprised of natural fibers (e.g., wood or cotton fibers), syntheticfibers (e.g., polymeric fibers such as polyester, polypropylene, orpolyethylene fibers) or from a combination of natural and syntheticfibers. The topsheet 54 can be rendered hydrophilic by treating it witha hydrophilic finishing oil or a surfactant. Suitable methods for thetreatment for the topsheet 54 include spraying the topsheet 54 materialwith surfactant and immersing the material into the surfactant. A moredetailed discussion of such a treatment and hydrophilicity is containedin U.S. Pat. No. 4,988,344 entitled “Absorbent Articles with MultipleLayer Absorbent Layers” issued to Reising, et al. on Jan. 29, 1991 andU.S. Pat. No. 4,988,345 entitled “Absorbent Articles with RapidAcquiring Absorbent Cores” issued to Reising on Jan. 29, 1991, each ofwhich is incorporated by reference herein. Alternatively, the topsheet24 may be a carded nonwoven material which is formed by fibers treatedwith hydrophilic finishing oil.

The backsheet 52 is that portion of the diaper 50 which is generallypositioned away from the wearer's skin and which prevents the exudatesabsorbed and contained in the absorbent core 66 from wetting articleswhich contact the diaper 50 such as bedsheets and garments. Thus, thebacksheet 52 is impervious to liquids (e.g., urine) and is preferablymanufactured from a thin plastic film, although other soft, flexibleliquid impervious materials may also be used. (As used herein, the term“flexible” refers to materials which are compliant and will readilyconform to the general shape and contours of the human body.) While thebacksheet 52 is impervious to liquids, the backsheet 52 permits moistureto escape from the diaper 50. The backsheet 52 may comprise a breathablemicroporous film 53 and an outer nonwoven sheet 55.

The microporous film 53 may comprise any known material being moisturepervious and liquid impervious. For example, the microporous film 53 maycomprise a breathable microporous film composed of a thermoplastic resinand inorganic fillers dispersed in the thermoplastic resin. Suitablethermoplastic polymers include polyolefins such as polyethylenes,including liner low density polyethylene (LLDPE), low densitypolyethylene (LDPE), ultra low density polyethylene (ULDPE), highdensity polyethylene (HDPE), or polypropylene and blends thereof withthe above and other materials. The inorganic filler and thethermoplastic polymer are blended together to form a homogeneous mixturein a suitable mixing extruder, or in a separate preliminary compoundingstep. The mixture is then cast or blown into a film. The obtained filmis stretched at least in one direction to impart breathability on thesubstantially entire area or a portion of the film.

The nonwoven outer sheet 55 may be joined with at least a portion of thegarment-facing surface of the microporous film 53. The nonwoven sheet 55may cover all or substantially all of the garment-facing surface of themicroporous film 53, or may cover only discrete predetermined portions.In a preferred embodiment, the nonwoven web of the nonwoven sheet 55covers all or substantially all of the microporous film 53 in order toprovide the diaper with a cloth-like look and feel.

The nonwoven web comprised in the nonwoven sheet 55 may comprise naturalfibers (e.g., cotton or wood fibers), or may comprise fibers ofpolyolefins such as polyethylene and polypropylene, polyester, or anycombination of such fibers. Polyolefin fibers are preferable. Further,the nonwoven may be carded, spunbond, meltblown or air-through bonded orhave any other characteristic or be manufactured in any manner known inthe art. An especially preferred nonwoven is a spunbonded nonwoven madeof 100% polypropylene fibers such as Mitsui Copoly PP nonwoven 20 gsm(designation code: PC-0220) supplied by Mitsui Chemical in Japan.

A moisture vapor transmission rate of the backsheet is important inreducing the incidence of heat rash and other skin problems associatedwith high humidity conditions. A moisture permeable substrate webprinted with an ink composition typically has less moisture permeabilitythan before being printed. This is because an ink film layer printed onthe substrate web tends to fill the open apertures or micropores formedin the moisture permeable substrate web to close the open apertures ormicropores. The reduction of moisture permeability of the substrate webcaused by an ink printing is more apparent in the moisture permeablesubstrate web formed by a microporous film than by a nonwoven becausethe size of micropores of a microporous film is much smaller than thatof apertures of a nonwoven and get readily closed or narrowed by the inkcomposition. Therefore, it is preferable to make an ink printing on anonwoven substrate to secure a required moisture permeability. Theink-printed nonwoven is joined to the microporous film prior to printingor after printing such that the ink-printed surface is exposed outsideand the opposite side of the ink-printed surface faces the microporousfilm. Such a laminate comprising an ink-printed nonwoven and amicroporous film enhances the aesthetic appearance and the consumeracceptance while maintaining a moisture permeability and liquidimpermeability.

A preferable uppermost amount of the ink composition applied in theink-printed area on the nonwoven may be not more than about 10 g/m²,preferably not more than about 6 g/m², more preferably not more thanabout 4 g/m². A preferable lowermost amount of the ink compositionapplied on the nonwoven may be not less than about 0.05 g/m², preferablynot less than about 0.1 g/m², more preferably not less than about 0.3g/m². Herein the term “ink-printed area” refers to the area in which theink composition is applied to a substrate web to make a visible objecton the substrate web. The amount of the ink composition is the totalamount of the ink compositions applied in the ink-printed area. Namely,if the ink-printed area is printed with a single color ink composition,the amount is that of the single color ink composition. If theink-printed area is printed with three different color ink compositions,the amount is the total amount of each different color ink composition.If the ink-printed area is further coated with a coating composition, apreferable uppermost total amount (basis weight) of the ink-compositionand the coating composition may be not more than about 10 g/m²,preferably not more than about 6 g/m², more preferably not more thanabout 4 g/m². A preferable uppermost amount of the coating compositionmay be not more than 9.95 g/m², preferably not more than about 9.9 g/m²,more preferably not more than about 9.7 g/m². In order for theink-printed nonwoven not to significantly reduce the moisturepermeability of the laminate, the amount of the ink composition appliedon the nonwoven is not preferably beyond the uppermost amount above. Ifthe ink-printed area is further coated with a coating composition, thetotal amount of the ink-composition and the coating compositionpreferably is not preferably beyond the uppermost total amount above.

A moisture vapor transmission rate of the laminate of the ink-printednonwoven and a microporous film in the maximum ink-printed portion isnot less than about 50%, preferably not less than about 60%, morepreferably not less than about 70% of a moisture vapor transmission rateof the laminate before being printed. Moisture vapor transmission rate(“MVTR”) is a characteristic measure of breathability. MVTR refers tothe permissible moisture volume from one side of the substrate web tothe other side of the substrate web per area unit (e.g., per squaremeter) and per time unit (e.g., per one day). The MVTR of a substrateweb may be measured by the Cup Test method. This method is described asfollows. A known amount of calcium chloride (CaCl2) is put into astainless steel container which is a cylindrical container with adiameter of 30 mm and a depth of 50 mm. The CaCl2 with water levelmeasurement useful herein may be purchased from Wako Pure Chemical Co.,Ltd. A substrate web test sample is placed on the top of the container,and the container is tightly closed with a cap and screws. The cap has ahole through it and thus moisture outside the container can diffuse intothe container through the substrate web test sample. The container withthe substrate web test sample is then placed in a constant temperature(40° C.) and humidity environment (75% relative humidity) for a fixedperiod of time. The amount of moisture absorbed by the CaCl2 in thecontainer is a measure of the moisture permeability of the substrateweb. A test sample is taken to have a circular shape with the diameterof 4 cm (the center 3 cm diameter portion is used for measurement andthe periphery portion is used to anchor the test sample to equipment formeasurement). When a moisture vapor transmission rate of the laminatecomprising a nonwoven and a microporous film before being printed ismeasured, a test sample may be taken from the laminate before an inkprinting is made onto the laminate in the manufacturing process.Instead, the laminate before being printed may be represented by anon-printed portion of the laminate assembled into a final product suchas an absorbent article. When a moisture vapor transmission rate of thelaminate of the ink-printed nonwoven and a microporous film in themaximum ink-printed portion is measured, a test sample is taken from thelaminate after an ink printing is made onto the laminate in themanufacturing process. Instead, the test sample may be taken from afinal product. Herein, “maximum ink-printed portion” means the portionof the laminate in which the rate of the ink-printed area to the area ofa specified area of the substrate web is maximum. The specified area ofthe substrate web can be defined by the method for measurement. When themoisture vapor transmission rate is measured by the above method, thespecified area corresponds to the area of the substrate web formeasurement and is the circular portion with the diameter of 3 cm.

A bending force of the ink-printed nonwoven used for, e.g., a backsheet,a side ear panel, a landing zone for a fastening system, or a tape for afastening system for an absorbent article is important for providingconsumers, i.e., caregiver and wearer, with softness and/or flexibility.A portion of the nonwoven printed with an ink composition typicallybecomes less soft/flexible than before being printed due to the inkcomposition forming a film layer on the nonwoven which gives somestiffness to the nonwoven. If the ink-printed area is further coatedwith a coating composition, the softness and/or flexibility of theink-printed nonwoven further reduces.

In order for the ink-printed nonwoven to have sufficient softness and/orflexibility, the amount of the ink composition applied on the nonwovenis not preferably beyond the uppermost amount above (i.e., the amount ofthe ink composition is preferably not more than about 10 g/m²,preferably not more than about 6 g/m², more preferably not more thanabout 4 g/m²). If the ink-printed area is further coated with a coatingcomposition, the total amount of the ink-composition and the coatingcomposition preferably is not preferably beyond the uppermost totalamount above (i.e., the total amount of the ink composition and thecoating composition is preferably not more than about 10 g/m²,preferably not more than about 6 g/m², more preferably not more thanabout 4 g/m²).

The ink-printed area of the nonwoven may have an average bending forcevalue of not more than about 50 mgf·cm²/cm, preferably not more thanabout 40 mgf·cm²/cm, and more preferably not more than about 35mgf·cm²/cm. The lower limit of the bending force may be determinedarbitrarily by the skilled in the art in balance with the requirement ofthe amount of the ink composition for clear graphics and the totalamount of the ink composition and the coating composition. As usedherein, “bending force” means the mechanical property defined as theslope of M-K curve shown in FIG. 5. M is bending momentum per unit widthand K is curvature. Bending force can be measured by the methoddescribed herein below.

A bending tester, KES-FB2, Kato Tech. Co Ltd., is used to measurebending force. The deformation mode is a pure bending between thecurvature K=−2.5 cm⁻¹ and 2.5 cm⁻¹. The effective dimension for themeasurement is 20 cm in length and 1 cm in width (rectangular).Therefore, the test sample is taken to have at least 20 cm in length and1 cm in width to include the maximum ink-printed portion of thesubstrate web. In this case, the specified area for determination of themaximum ink-printed portion is 20 cm in length and 1 cm in width. Thetest sample is bent as shown in FIGS. 3 and 4. The bending rate is 0.5cm⁻¹/sec. As a result, the bending hysteresis curve as shown in FIG. 5is obtained by the measurement. The horizontal axis shows the curvaturesK cm⁻¹ and the vertical axis shows the bending moment per unit width M(gf·cm/cm). The bending force is calculated as follows:Bending Force=(Bf+Bb)/2

where Bf and Bb are the slopes of the hysteresis curves between K=0.5cm⁻¹ and 1.5 cm⁻¹ and K=−0.5 cm⁻¹ and −1.5 cm⁻¹ respectively.

Measurements are carried out in the MD and CD directions of the same webtest sample. The average bending force is the mean value of the abovebending force obtained from the measurements about the MD and CDdirections of the test sample.

A fuzz level of the ink-printed nonwoven used for, e.g., a backsheet, aside ear panel, a landing zone for a fastening system, or a tape for afastening system for an absorbent article is important for reducing fuzzof fibers on the ink-printed nonwoven. The fuzzy fibers can collect dustinto the fuzzy fibers to contaminate the surface of the nonwoven andprovide consumers with an impression of poor appearance. Further theink-printed nonwoven printed with multi-color loses clearness and/orsharpness of the multi-color images due to the fuzzed fibers. Becausethe ink composition which forms an ink film layer tends to providebinding to the fibers of the nonwoven, the fibers have a reducedtendency to become fuzzy. The ink composition which can form across-linked structure is also useful to provide a binding force to thefibers. When the ink composition is further coated with a coatingcomposition which can form a cross-linked structure within the coatingcomposition, the binding force of the fibers becomes high to furtherreduce the fuzz of the fibers. When the ink composition and the coatingcomposition form a cross-linked structure to each other, the bindingforce of the fibers is further enhanced.

In order for the ink-printed nonwoven to have a reduced fuzz level, theamount of the ink composition applied on the nonwoven is not preferablybelow the lowermost amount above (i.e., the amount of the inkcomposition is preferably not less than about 0.01 g/m², preferably notless than about 0.05 g/m², more preferably not less than about 0.07g/m²). When the ink composition is not less than these lowermost ranges,it is also possible to provide an aesthetic appearance and a consumeracceptance by the ink-printed graphics.

The ink-printed area of the nonwoven may have a Fuzz Level (FL) of notmore than about 0.25 mg/cm², preferably not more than about 0.2 mg/cm²,and more preferably from about 0.15 mg/cm². The method for measuring theFuzz Level of nonwoven webs or layers is explained hereinbelow.

To measure the quantity of untangled fibers that protrude from thesurface of the test sample, as shown in FIG. 6, the face of the sample12 is rubbed against the face of sandpaper 14 for 29 seconds at 0.7 Hzto cut or loose the untangled fibers 16. 2000 gf/cm² of pressure isapplied to the sample 12. An example of the equipment is shown in FIG.6. The cut fibers produced by this action are collected by a removaltape and quantified with an analytical balance. The fuzz level isdefined as the weight of the fibers collected per unit area (mg/cm²).

An example of equipment available is Sutherland Ink Rub Tester. 2000gf/cm² of pressure is applied to the test sample. This apparatus abradesa 4 cm×11 cm piece of test sample with a 15 cm×5.1 cm piece of sandpaper(Matelite K224 Cloth Sandpaper Grit 320-J, Norton Co., Troy, N.Y.).Therefore, the test sample is taken to have at least 11 cm in length and4 cm in width to include the maximum ink-printed portion of thesubstrate web. In this case, the specified area for determination of themaximum ink-printed portion is 11 cm in length and 4 cm in width. Therub cycle is 20 times at 0.7 cycle/sec. The fibers (fuzz) are removedusing two 15 cm×5.1 cm pieces of removal tape (3M No. 3187 Trans Tape,Cincinnati, Ohio) from both the sandpaper and the test sample.

An ink-printed substrate of the present invention such as an ink-printednonwoven used for, e.g., a backsheet, a side ear panel, a landing zonefor a fastening system, or a tape for a fastening system for anabsorbent article should have minimal ink rub-off amount during the useof the ink-printed nonwoven. The ink rub-off amount is not more than0.05 mg/cm², preferably not more than 0.03 mg/cm², more preferably notmore than 0.01 mg/cm².

The ink rub-off amount is measured by using a rubbing procedure andequipment for rubbing as described in Japanese Industrial Standard testmethod for color fastness to rubbing. The method used is JIS L 0849.There are two types of apparatus indicated in the method; Rubbing testerI and Rubbing tester II. Rubbing tester II (Gakushin Type) is usedherein. The test sample size used for the test is 220 mm length and 30mm width. The sample should be cut in such a way that the maximumink-printed portion of the substrate comes in the middle of the sample.It should be ensured that the maximum ink-print portion comes in contactwith the white cotton swatch attached to the rubbing finger when rubbed.The 100 mm×20 mm area of the test sample which is being rubbed by thewhite cotton swatch attached to the rubbing finger should contain themaximum ink-printed portion. Therefore, the determination of the maximumink-printed position is 100 mm×20 mm. In cases where the specifiedsample size could not be cut, small size sample can be attached to anun-printed test sample of the same substrate of the specified testsample size. There are two different procedures indicated in the method;Dry rubbing test and Wet rubbing test. Wet rubbing test is used herein.In Wet rubbing test, the water should be a distilled water.

The amount of ink rubbed off to a standard white cotton swatch ismeasured using UV spectroscopy. First, a known weight of coloring agentssuch as pigments or colorants corresponding to the colors used forprinting is dissolved in a solvent. The solvent needs to be selected insuch a way that there is no UV absorption of the solvent in thewavelength range where the coloring agent has the UV absorption. Anysolvent which can dissolve the coloring agent and which do not interferewith the UV absorption spectra of the coloring agent can be used.Exemplary solvents used for the current test is N-N dimethylformamide oro-Chlorophenol. The UV absorption spectra of the solution is recordedusing a UV spectrophotometer UV-3101PC of Shimadzu Corporation, Japan inthe range of 300 nm-850 nm. The concentration of the solution isadjusted to get spectra with in the measurable range. Second, the inkrubbed off to the cotton swatch area of 20 mm×20 mm is dissolved in theselected solvent by immersing the cotton swatch in the solvent. Theswatch should be immersed in the solvent for time period and at atemperature required to dissolve the coloring agent completely from thecotton swatch to the solvent.

The UV spectra of the dissolved coloring agent is measured in the rangeof 300 nm-850 nm. In the case of multi-colored printing, differentabsorption range corresponding to the colors used will appear in thespectra. The amount of each coloring agent which is dissolved from thecotton swatch can be estimated by comparing with the spectra of thesolution for the known amount of coloring agent. If the UV absorptionspectra of the coloring agent solution dissolved from the white cottonswatch gives well defined absorption peaks with well defined base line,the area under these peaks can be compared with the area under peak ofthe UV absorption spectra of the solution for the known amount ofcoloring agent. If the peaks are not well defined and if the base linecan not be drawn, differential of the spectra can be used to getaccurate results. The amount of ink rubbed-off to the white cottonswatch is expressed in terms of weight of the rubbed-off ink per unitarea of the white cotton swatch (e.g., mg/cm²).

EXAMPLES

The following examples further describe and demonstrate the preferredembodiments within the scope of the present invention. The examples aregiven solely for the purpose of illustration, and are not to beconstrued as limitations of the present invention since many variantsthereof are possible without departing from its spirit and scope.

Example 1

A spunbonded nonwoven web comprising polypropylene fibers with basisweight of 33 g/m² is used as a substrate web. It is continuouslysupplied and applied with corona discharging treatment by Sherman CoronaTreater supplied by Sherman Treaters at the corona discharging power of58 W·m2/min. An ink composition is a red based ink composition andcomprises a first base component and a first hardening component asspecified below respectively. The first base component and the firsthardening component are mixed prior to printing to form the inkcomposition. The corona treated nonwoven is printed with the inkcomposition by using a flexographic printing machinery at a speed ofapproximately 150 m/min. The amount of the ink composition applied is 1g/m². A coating composition comprises a second base component and asecond hardening component as specified below respectively. The secondbase component and the second hardening component are mixed prior tocoating to form the coating composition. The ink composition printed onthe nonwoven web is coated with the coating composition with 2 g/m². Theprinted and over coated nonwoven is then dried by evaporating thesolvent and is then aged at room temperature (i.e., 25° C.) for 24hours. Ink Composition First base component 90% First hardeningcomponent 10% First base component Binder Polymer Polyurethane resin5.0% Polyvinyl butyral resin 7.5% Coloring Agent C.I. Pigment Red 48-310.0% Solvent 1-propanol 41.6% 2-Propanol 1.2% Ethyl acetate 4.7% Propylacetate 20.5% Ethyl alcohol 2.6% Additives Polyethylene wax 3.3%Cellulose Nitrate 0.6% Shellac 3.0% First hardening component HardenerPolyisocyanate 37.5% Solvent Ethyl acetate 62.5%

Coating Composition Second base component 90% Second hardening component10% Second base component Binder Polymer Polyurethane resin 12.5%Polyvinyl butyral resin 8.0% Solvent 1-propanol 14.1% 2-Propanol 51.4%Ethyl acetate 2.7% Propyl acetate 6.9% Additives Polyethylene wax 3.4%Silica 1.0% Second hardening component Hardener Polyisocyanate 37.5%Solvent Ethyl acetate 62.5%

Example 2

The spunbonded nonwoven web of Example 1 is printed with a red basedink, a blue based ink and an yellow based ink in its order, and thencoated with the coating composition. The red based ink composition isthe same as Example 1. The blue based ink composition contains C.I.Pigment Blue 15-4 as a coloring agent instead of C.I. Pigment Red 48-3of the red based ink composition of Example 1 while the rest of thecomponents of the blue based ink composition is the same as those of thered based ink composition of Example 1. The yellow based ink compositioncontains C.I. Pigment Yellow 14 as a coloring agent instead of C.I.Pigment Red 48-3 of the red based ink composition of Example 1 while therest of the components of the yellow based ink composition is the sameas those of the red based ink composition of Example 1. The total amountof the three ink compositions applied is 1 g/m². The rest of theconditions are the same as Example 1.

Example 3

An extrusion laminate of a carded nonwoven comprising polypropylenefibers with 18 g/m² and a microporous breathable film comprising linerlow density polyethylene and calcium carbonate fillers is used as asubstrate web. A mixture of liner low density polyethylene and calciumcarbonate fillers is extruded onto a carded nonwoven to form anextrusion laminate. The extrusion laminate is then mechanicallystretched to impart breathability in the microporous breathable film.The nonwoven has two surfaces: a film facing surface and an exposedsurface opposite to the film facing surface. The printing and coatingare made on the exposed surface of the nonwoven. The rest of conditionsare the same as Example 2.

Example 4

A spunbonded nonwoven web comprising polypropylene fibers with basisweight of 33 g/m² is used as a substrate web. The nonwoven web isprinted with a red based ink, a blue based ink, and a yellow based inkits order. A red based ink composition comprises a first base componentand a first hardening component as specified below respectively. A bluebase ink composition contains C.I. Pigment Blue 15-4 as a coloring agentinstead of C.I. Pigment Red 48-3 of the red based ink composition belowwhile the rest of the components of the blue based ink composition isthe same as those of the red based ink composition below. The yellowbased ink composition contains C.I. Pigment Yellow 14 as a coloringagent instead of C.I. Pigment Red 48-3 of the red based ink compositionbelow while the rest of the components of the yellow based inkcomposition is the same as those of the red based ink composition below.The first base component and the first hardening component of each ofthe red, blue, and yellow based inks are mixed prior to printing to formeach color of the ink composition respectively. The nonwoven is printedwith the ink composition by using a flexographic printing machinery at aspeed of approximately 150 m/min. The amount of the three inkcompositions applied is 1.5 g/m². A coating composition comprises asecond base component and a second hardening component as specifiedbelow respectively. The second base component and the second hardeningcomponent are mixed prior to coating to form the coating composition.The ink composition printed on the nonwoven web is coated with thecoating composition with 4 g/m². The printed and over coated nonwoven isthen dried by evaporating the solvent and is then aged at roomtemperature (i.e., 25° C.) for 24 hours. Ink Composition First basecomponent 80% First hardening component 20% First base component BinderPolymer Polyurethane resin  5.0% Polyvinyl butyral rein  7.5% ColoringAgent C.I. Pigment Red 48-3 10.0% Solvent 1-propanol 41.6% 2-Propanol 1.2% Ethyl acetate  4.7% Propyl acetate 20.5% Ethyl alcohol  2.6%Additives Polyethylene wax  3.3% Cellulose Nitrate  0.6% Shellac  3.0%First hardening component Hardener Polyisocyanate 37.5% Solvent Ethylacetate   5%

Coating Composition Second base component 80% Second hardening component20% Second base component Binder Polymer Polyurethane resin 12.5%Polyvinyl butyral resin 8.0% Solvent 1-propanol 14.1% 2-Propanol 51.4%Ethyl acetate 2.7% Propyl acetate 6.9% Additives Polyethylene wax 3.4%Silica 1.0% Second hardening component Hardener Polyisocyanate 37.5%Solvent Ethyl acetate 62.5%

Example 5

A spunbonded nonwoven web comprising polypropylene fibers with basisweight of 33 g/m² is used as a substrate web. The nonwoven web isprinted with a red based ink, a blue based ink, and a yellow based inkin its order. A red based ink composition comprises a first basecomponent as specified below. A blue base ink composition contains C.I.Pigment Blue 15-4 as a coloring agent instead of C.I. Pigment Red 48-3of the red based ink composition below while the rest of the componentsof the blue based ink composition is the same as those of the red basedink composition below. The yellow based ink composition contains C.I.Pigment Yellow 14 as a coloring agent instead of C.I. Pigment Red 48-3of the red based ink composition below while the rest of the componentsof the yellow based ink composition is the same as those of the redbased ink composition below. The nonwoven is printed with the inkcomposition by using a flexographic printing machinery at a speed ofapproximately 150 m/min. The amount of the three ink compositionsapplied is 1 g/m². A coating composition comprises a second basecomponent and a second hardening component as specified belowrespectively. The second base component and the second hardeningcomponent are mixed prior to coating to form the coating composition.The ink composition printed on the nonwoven web is coated with thecoating composition with 1.5 g/m².

The printed and over coated nonwoven is then dried by evaporating thesolvent and is then aged at room temperature (i.e., 25° C.) for 24hours. Ink Composition First base component 100% First base componentBinder Polymer Polyurethane resin 5.0% Polyvinyl butyral rein 7.5%Coloring Agent C.I. Pigment Red 48-3 10.0% Solvent 1-propanol 41.6%2-Propanol 1.2% Ethyl acetate 4.7% Propyl acetate 20.5% Ethyl alcohol2.6% Additives Polyethylene wax 3.3% Cellulose Nitrate 0.6% Shellac 3.0%

Coating Composition Second base component 90% Second hardening component10% Second base component Binder Polymer Polyurethane resin 12.5%Polyvinyl butyral resin 8.0% Solvent 1-propanol 14.1% 2-Propanol 51.4%Ethyl acetate 2.7% Propyl acetate 6.9% Additives Polyethylene wax 3.4%Silica 1.0% Second hardening component Hardener Polyisocyanate 37.5%Solvent Ethyl acetate 62.5%

Example 6

The nonwoven web of Example 5 is continuously supplied and applied withcorona discharging treatment by Sherman Corona Treater supplied bySherman Treaters at the corona discharging power of 58 W·m²/min, beforebeing printed with an ink composition. Then the corona treated nonwovenweb is printed with an ink composition. The rest of conditions are thesame as Example 5.

Example 7

A spunbonded nonwoven web comprising polypropylene fibers with basisweight of 33 g/m² is used as a substrate web. The nonwoven web isprinted with a red based ink, a blue based ink, and a yellow based inkin its order. A red based ink composition comprises a first basecomponent and a first hardening component as specified belowrespectively. A blue base ink composition contains C.I. Pigment Blue15-4 as a coloring agent instead of C.I. Pigment Red 48-3 of the redbased ink composition below while the rest of the components of the bluebased ink composition is the same as those of the red based inkcomposition below. The yellow based ink composition contains C.I.Pigment Yellow 14 as a coloring agent instead of C.I. Pigment Red 48-3of the red based ink composition below while the rest of the componentsof the yellow based ink composition is the same as those of the redbased ink composition below. The first base component and the firsthardening component of each of the red based, the blue based and theyellow based inks are mixed prior to printing to form each color of theink composition respectively. The nonwoven is printed with the inkcomposition by using a flexographic printing machinery at a speed ofapproximately 150 m/min. The amount of the three ink compositionsapplied is 1 g/m². A coating composition comprises a second basecomponent as specified below respectively. The ink composition printedon the nonwoven web is coated with the coating composition with 2 g/m².The printed and over coated nonwoven is then dried by evaporating thesolvent and is then aged at room temperature (i.e., 25° C.) for 24hours. Ink Composition First base component 90% First hardeningcomponent 10% First base component Binder Polymer Polyurethane resin5.0% Polyvinyl butyral rein 7.5% Coloring Agent C.I. Pigment Red 48-310.0% Solvent 1-propanol 41.6% 2-Propanol 1.2% Ethyl acetate 4.7% Propylacetate 20.5% Ethyl alcohol 2.6% Additives Polyethylene wax 3.3%Cellulose Nitrate 0.6% Shellac 3.0% First hardening component HardenerPolyisocyanate 37.5% Solvent Ethyl acetate 62.5%

Coating Composition Second base component 100% Second base componentBinder Polymer Polyurethane resin 12.5% Polyvinyl butyral resin 8.0%Solvent 1-propanol 14.1% 2-Propanol 51.4% Ethyl acetate 2.7% Propylacetate 6.9% Additives Polyethylene wax 3.4% Silica 1.0%

Example 8

The nonwoven web of Example 7 is continuously supplied and applied withcorona discharging treatment by Sherman Corona Treater supplied bySherman Treaters at the corona discharging power of 58 W·m²/min, beforebeing printed with an ink composition. Then the corona treated nonwovenweb is printed with an ink composition. The rest of conditions are thesame as Example 7.

Example 9

A spunbonded nonwoven web comprising polypropylene fibers with basisweight of 33 g/m² is used as a substrate web. It is continuouslysupplied and applied with corona discharging treatment by Sherman CoronaTreater supplied by Sherman Treaters at the corona discharging power of58 W·m²/min. An ink composition is a red based ink composition andcomprises a first base component and a first hardening component asspecified below respectively. The first base component and the firsthardening component are mixed prior to printing to form the inkcomposition. The corona treated nonwoven is printed with the inkcomposition by using a flexographic printing machinery at a speed ofapproximately 150 m/min. The amount of the ink composition applied is 2g/m². A coating composition comprises a second base component and asecond hardening component as specified below respectively. The secondbase component and the second hardening component are mixed prior tocoating to form the coating composition. The ink composition printed onthe nonwoven web is coated with the coating composition with 3 g/m². Theprinted and over coated nonwoven is then dried by evaporating thesolvent and is then aged at room temperature (i.e., 25° C.) for 24hours. Ink Composition First base component 80% First hardeningcomponent 20% First base component Binder Polymer Polyurethane resin15.5% Coloring Agent C.I Pigment Red 48-3 10.0% Solvent 1-propanol 27.1%2-Propanol 18.2% Ethyl acetate 4.7% Propyl acetate 20.6% AdditivesPolyethylene wax 3.3% Cellulose Nitrate 0.6% First hardening componentHardener Polyisocyanate 37.5% Solvent Ethyl acetate 62.5%

Coating Composition Second base component 90% Second hardening component10% Second base component Binder Polymer Polyurethane resin 22.0%Solvent 1-propanol 21.1% 2-Propanol 27.3% Ethyl acetate 3.7% Propylacetate 21.3% Additives Polyethylene wax 3.6% Silica 1.0% Secondhardening component Hardener Polyisocyanate 37.5% Solvent Ethyl acetate62.5%

Example 10

A spunbonded nonwoven web comprising polypropylene fibers with basisweight of 33 g/m² is used as a substrate web. It is continuouslysupplied and applied with corona discharging treatment by Sherman CoronaTreater supplied by Sherman Treaters at the corona discharging power of58 W·m²/min. An ink composition is a red based ink composition andcomprises a first base component and a first hardening component asspecified below respectively. The first base component and the firsthardening component are mixed prior to printing to form the inkcomposition. The corona treated nonwoven is printed with the inkcomposition by using a flexographic printing machinery at a speed ofapproximately 150 m/min. The amount of the ink composition applied is 1g/m². A coating composition comprises a second base component and asecond hardening component as specified below respectively. The secondbase component and the second hardening component are mixed prior tocoating to form the coating composition. The ink composition printed onthe nonwoven web is coated with the coating composition with 1 g/m². Theprinted and over coated nonwoven is then dried by evaporating thesolvent and is then aged at room temperature (i.e., 25° C.) for 24hours. Ink Composition First base component 90% First hardeningcomponent 10% First base component Binder Polymer Polyurethane resin29.0% Coloring Agent C.I. Pigment Red 48-3 10.0% Solvent 1-propanol11.5% 2-Propanol 12.9% Ethyl acetate 12.1% Propyl acetate 9.0% Propyleneglycol monomethyl 5.7% ether Propyl glycol 5.0% Additives Polyethylenewax 3.6% Cellulose Nitrate 1.2% First hardening component HardenerPolyisocyanate 37.5% Solvent Ethyl acetate 62.5%

Coating Composition Second base component 90% Second hardening component10% Second base component Binder Polymer Polyurethane resin 32.0%Solvent 1-propanol 12.8% 2-Propanol 15.4% Ethyl acetate 15.7% Propylacetate 9.0% Propylene glycol monomethyl 5.3% ether Propyl glycol 5.0%Additives Polyethylene wax 3.6% Silica 1.2% Second hardening componentHardener Polyisocyanate 37.5% Solvent Ethyl acetate 62.5%Statements of Incorporation by Reference and Intended Scope of Claims

The disclosures of all patents, patent applications and any patentswhich issue thereon, as well as any corresponding published foreignpatent applications, and all publications listed and/or referenced inthis description, are hereby incorporated herein by reference. It isexpressly not admitted that any of the documents or any combination ofthe documents incorporated herein by reference teaches or discloses thepresent invention. To the extent that any meaning or definition of aterm in this document conflicts with any meaning or definition of thesame term in a document incorporated by reference, the meaning ordefinition assigned to that term in this document shall govern.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various changes and modifications can be made without departingfrom the spirit and scope of the invention. It is therefore intended tocover in the claims all such changes and modifications that are withinthe scope of this invention.

1. A disposable diaper comprising: a liquid permeable topsheet; a liquidimpermeable backsheet; and an absorbent core disposed between thetopsheet and the backsheet, the backsheet comprising an ink-printedsubstrate web comprising a laminate of a polymeric film web and asynthetic nonwoven web, the film web being disposed adjacent to theabsorbent core and the nonwoven web being disposed opposite theabsorbent core, the nonwoven web having a surface facing toward thepolymeric film web and an opposing outer surface; an ink compositionforming an ink film on the outer surface of the nonwoven web; and acoating composition forming a coating film on the ink film and therebysandwiching the ink film between the coating film and the nonwoven web,wherein at least the ink composition forms a first ink compositioncross-linked structure within the ink film and forms a firstintercomposition cross-linked structure with the coating compositionbetween the ink film and the coating film, or the coating compositionforms a first coating composition cross-linked structure within thecoating film and forms the first intercomposition cross-linked structurewith the ink composition between the coating film and the ink film. 2.The disposable diaper of claim 1 wherein the synthetic nonwoven web ismade of a polyolefin.
 3. The disposable diaper of claim 1 wherein thecoating composition forms the first coating composition cross-linkedstructure within the coating film and forms the first intercompositioncross-linked structure with the ink composition between the coating filmand the ink film.
 4. The disposable diaper of claim 1 wherein the inkcomposition forms the first ink composition cross-linked structurewithin the ink film and forms the first intercomposition cross-linkedstructure with the coating composition between the ink film and thecoating film.
 5. The disposable diaper of claim 1 wherein the inkcomposition forms the first ink composition cross-linked structurewithin the ink film, the coating composition forms the first coatingcomposition cross-linked structure within the coating film, the inkcomposition forms the first intercomposition cross-linked structure withthe coating composition between the ink film and the coating film, andthe coating composition forms a second intercomposition cross-linkedstructure with the ink composition between the coating film and the inkfilm.
 6. The disposable diaper of claim 1 wherein the ink compositioncomprises an ink composition binder polymer and an ink compositionhardener forming the first ink composition cross-linked structure withthe ink composition hardener and forming the first intercompositioncross-linked structure with a coating composition binder polymer, or thecoating composition comprises a coating composition binder polymer and acoating composition hardener forming the first coating compositioncross-linked structure and forming the first intercompositioncross-linked structure with an ink composition binder polymer.
 7. Thedisposable diaper of claim 1 wherein the ink composition comprises anink composition binder polymer and a coloring agent, the coatingcomposition comprises a coating composition binder polymer and a coatingcomposition hardener, and the coating composition hardener forms thefirst coating composition cross-linked structure with the coatingcomposition binder polymer and forms the first intercompositioncross-linked structure with the ink composition binder polymer.
 8. Thedisposable diaper of claim 1 wherein the ink composition comprises anink composition binder polymer, an ink composition hardener and acoloring agent, the coating composition comprises a coating compositionbinder polymer, and the ink composition hardener forms the first inkcomposition cross-linked structure with the ink composition binderpolymer and forms the first intercomposition cross-linked structure withthe coating composition binder polymer.
 9. The disposable diaper ofclaim 1 wherein the ink composition comprises a first binder polymer, afirst hardener and a coloring agent, the coating composition comprises asecond binder polymer and a second hardener, the first hardener forms across-linked structure with the first binder polymer and the secondbinder polymer, and the second hardener forms a cross-linked structurewith the first binder polymer and the second binder polymer.
 10. Thedisposable diaper of claim 1 wherein an ink rub-off amount of anink-printed area of the ink-printed substrate web is not more than about0.05 mg/cm².
 11. A disposable diaper comprising: a liquid permeabletopsheet; a liquid impermeable backsheet; and an absorbent core disposedbetween the topsheet and the backsheet, the backsheet comprising anink-printed substrate web comprising a laminate of a polymeric film weband a synthetic nonwoven web, the film web being disposed adjacent tothe absorbent core and the nonwoven web being disposed opposite theabsorbent core, the nonwoven web having a surface facing toward thepolymeric film web and an opposing outer surface; an ink compositionforming an ink film on the outer surface of the nonwoven web; and acoating composition forming a coating film on the ink film and therebysandwiching the ink film between the coating film and the nonwoven web,wherein the ink composition forms an ink composition cross-linkedstructure within the ink film and the coating composition forms acoating composition cross-linked structure within the coating film. 12.The disposable diaper of claim 11 wherein the ink composition comprisesan ink composition binder polymer, an ink composition hardener, and acoloring agent, the coating composition comprises a coating compositionbinder polymer, and a coating composition hardener, the ink compositionhardener forms the ink composition cross-linked structure with the inkcomposition binder, and the coating composition hardener forms thecoating composition cross-linked structure with the coating compositionbinder.
 13. A method for making a disposable diaper comprising anink-printed substrate web, the method comprising the steps of: providinga substrate web comprising a laminate of a polymeric film web and asynthetic nonwoven web, the nonwoven web having a surface facing towardthe polymeric film web and an opposing outer surface; printing thesubstrate web with an ink composition to form an ink film on the outersurface of the nonwoven web; coating the ink film with a coatingcomposition to form a coating film on the ink film and thereby sandwichthe ink film between the coating film and the nonwoven web; curing thecoating composition such that at least the ink composition forms a firstink composition cross-linked structure within the ink film and forms afirst intercomposition cross-linked structure with the coatingcomposition between the ink film and the coating film, or the coatingcomposition forms a first coating composition cross-linked structurewithin the coating film and forms the first intercompositioncross-linked structure with the ink composition between the coating filmand the ink film; providing an absorbent core such that the film web isdisposed adjacent to the absorbent core and the nonwoven web is disposedopposite the absorbent core; joining a liquid permeable topsheet to thesubstrate web so as to sandwich the absorbent core between the topsheetand the film web and thereby form the diaper.
 14. The method of claim 13wherein the synthetic nonwoven web is made of a polyolefin.
 15. Themethod of claim 13 wherein the coating composition forms the firstcoating composition cross-linked structure within the coating film andforms the first intercomposition cross-linked structure with the inkcomposition between the coating film and the ink film.
 16. The method ofclaim 13 wherein the ink composition forms the first ink compositioncross-linked structure within the ink film and forms the firstintercomposition cross-linked structure with the coating compositionbetween the ink film and the coating film.
 17. The method of claim 13wherein the ink composition forms the first ink composition cross-linkedstructure within the ink film, the coating composition forms the firstcoating composition cross-linked structure within the coating film, theink composition forms the first intercomposition cross-linked structurewith the coating composition between the ink film and the coating film,and the coating composition forms a second intercomposition cross-linkedstructure with the ink composition between the coating film and the inkfilm.
 18. The method of claim 13 wherein the ink composition forms thefirst ink composition cross-linked structure within the ink film and thecoating composition forms the coating composition cross-linked structurewithin the coating film.
 19. The method of claim 18 wherein the inkcomposition comprises an ink composition binder, an ink compositionhardener, and a coloring agent, the coating composition comprises acoating composition binder and a coating composition hardener, the inkcomposition hardener forms the first ink composition cross-linkedstructure with the ink composition binder, and the coating compositionhardener forms the first coating composition cross-linked structure withthe coating composition binder.
 20. The method of claim 13 wherein anink rub-off amount of an ink-printed area of the ink-printed substrateweb is not more than about 0.05 mg/cm².